Electropneumatics

Exercises and worksheets
Exercise 1: Inspecting beverage crates ________________________________________________________ 3

Exercise 2: Opening and closing a supply pipe _________________________________________________ 15
Exercise 3: Sealing cans ___________________________________________________________________ 25
Exercise 4: Filling plastic pellets _____________________________________________________________ 35
Exercise 5: Diverting packages ______________________________________________________________ 45
Exercise 6: Pushing boards out of a stacking magazine __________________________________________ 55
Exercise 7: Optimizing the inspection of beverage crates ________________________________________ 67
Exercise 8: Shifting roller conveyors _________________________________________________________ 79
Exercise 9: Transferring bottles _____________________________________________________________ 89
Exercise 10: Stamping mounting wedges ____________________________________________________ 101
Exercise 11: Palletizing roof tiles ___________________________________________________________ 111
Exercise 12: Eliminating a malfunction at a pallet loading station _________________________________ 121
© Festo Didactic 541090 1

2 © Festo Didactic 541090
Exercise 1: Inspecting beverage crates
Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of a single-acting cylinder.
• You’ll be familiar with the setup and function of a 3/2-way solenoid valve.
• You’ll be able to recognize and sketch the various types of actuation used for directional control valves.
• You’ll be able to explain and set up direct actuation.
Description of the problem

Beverage crates are checked for completeness with the help of an inspection unit. Incomplete crates are
pushed off of the roller conveyor by pressing a pushbutton.
Develop a controller with which this process can be executed
Layout
Inspection unit for beverage crates

Description of the process

1. Beverage crates are inspected at a manual workstation.
2. After pressing a pushbutton, incompletely filled beverage crates are pushed off of the conveyor by the
piston rod of a single-acting cylinder.
3. When the pushbutton is released, the piston rod is retracted to the rear end position.
General conditions
• A single-acting cylinder will be used.
• The cylinder will be controlled by means of a pushbutton.
• In the event of a power failure, the cylinder’s piston rod should be retracted to the rear end position.
Work assignments
1. Describe the function of pneumatic power components.
2. Complete the circuit symbols for solenoid valves.
3. Describe the meaning and the function of the port designations for valves.
4. Describe how the neutral positions of directional control valves influence the motion sequence of a
cylinder.
5. Describe the functions of various valve types.
6. Explain the difference between direct and indirect actuation.
7. Describe the design and function of electrical switches.
8. Complete the pneumatic and electrical circuit diagrams.
9. Complete the equipment list.
10. Set up the controller’s pneumatic and electrical sections.
11. Double check the controller configuration.
12. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
4 Name: __________________________________ Date: ____________ © Festo Didactic 541090

1. Function of pneumatic power components
Pneumatic power components can be subdivided into two groups:

• Power components with motion in a straight line
• Power components with rotary motion
– Describe the power components shown below and their functions.
Single Acting Cylinder with air cushioning, spring actuated air return
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Function
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When the rod extracted it can push objects in front, when air is supply to the cylinder it causes
the cylinder to retract.
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Single acting cylinder with air cushioning, air actuated, spring return
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Function
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© Festo Didactic 541090 Name: __________________________________ Date: ____________ 5

Rotary Cylinder
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Function
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2. Circuit symbols for solenoid valves
– Complete the circuit symbols with the help of the descriptions of the respective components.
Directly actuated 3/2-way solenoid valve, normally open, with manual override, pneumatic spring return
Pilot-actuated 3/2-way solenoid valve, normally closed, with manual override, mechanical spring return

3. Identification of valve ports
In order to prevent incorrect tubing connections at directional control valves, the valve
ports (working and pilot lines) are identified in accordance with ISO 5599-3 on the
valves themselves, as well as in the circuit diagram.
– Explain the meanings and functions of the port designations listed below.
Port designation Meaning and function
1 Supply Port
2, 4 Working Port
3, 5
Exhaust port
12 Open flow from 1 to 2
14
Open flow from 1 to 4
10 blocks flow from 1 to 2
82/84 Pilot Air

4. Directional control valve neutral position
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be
in the neutral position (unactuated) or the switched position (actuated). The valve can
be either closed or open in its neutral position.
– A single-acting cylinder is controlled by an electrically actuated 3/2-way solenoid valve. Describe how
the two different neutral positions effect the motion sequence of the cylinder:
3/2-way solenoid valve, normally closed

The initial position of the cylinder is in retracted state.
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3/2-way solenoid valve, normally open

The initial position of the cylinder is in extended state
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5. Functions of various valve types
Electrically actuated directional control valves are switched with the help of solenoid
coils (electromagnets). In principle, they can be subdivided into two groups:
• Federrückgestellte Magnetventile
• Magnetimpulsventile
– Explain the difference between the two groups with regard to function and performance in the event of
electrical power failure.
Solenoid valve with spring return
During a power failure the cylinder will go back to its original position by the help of spring
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Double solenoid valve
During power failure the cylinder cannot go back to its original postions
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6. Direct and indirect actuation
– Explain the difference between direct and indirect actuation based on the following application:
Electrical actuation of a 3/2-way solenoid valve with return spring by means of a pushbutton.
Direct actuation
When the pushbutton is pressed, the solenoid valve be will powered
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Indirect actuation
When the push button is pressed, the relay will be powered and it translates the open contract circuit into
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closed contact circuit which energized the solenoid valve
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7. Design and function of electrical switches
– Describe the design and function of the switches depicted below.
Design
Normally opened contact, manually operated by pressing
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Function
When the push button is pressed, it enables the flow of electricity in the circuit
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Design
Normally close contact, manually operated by pressing with detent
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Function
Alter the flow of the electricity when the push button is pressed
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Design
Change over switch
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Function
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8. Completing the pneumatic and electrical circuit diagrams
– Complete the pneumatic and electrical circuit diagrams for the inspection unit. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
Pneumatic circuit diagram Electrical circuit diagram

9. Completing the equipment list
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Quantity Identification Designation
1 -XM1 Distributor block
1 -AZ1 On-off valve with filter regulating valve
1 – Compressed air source
Pneumatic components
1 – 24 V DC power pack
Electrical components
10. Setting up the pneumatic and electrical sections of the control system
Observe the following points when setting up the control system:
• Use the circuit diagrams.
• Designate the components.
• Lay compressed air tubing using the shortest possible routes.
• Push the compressed air tubing into the push-in connector as far as it will go.
• Mark the connected compressed air tubing on the pneumatic circuit diagram.
• Establish the electrical connections with laboratory safety cables.
• Mark the connected laboratory safety cables on the electrical circuit diagram.

11. Double checking the control system setup

Observe the following points when commissioning the controller:
• Check all tubing connectors.
• Switch on 24 V supply power.
• Switch on compressed air supply at the service unit.
• Set the one-way flow control valve to maintain an advancing time of approx. 1 second. Use a stopwatch
to this end.
• Allow the control system to run through several complete cycles.
CAUTION
• Risk of injury when switching on compressed air!
Cylinders may advance and retract automatically.
• Risk of injury if compressed air tubing slips off!
If compressed air tubing slips off, shut off compressed air supply immediately
12. Describing the controller sequence
– Describe the individual steps of the controller sequence.
Initial position
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Step 1-2
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Step 2-3
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Exercise 2: Opening and closing a supply pipe
Learning objectives
• You’ll be familiar with the setup and function of a double-acting cylinder.
• You’ll be able to explain and set up direct actuation.

Numerous pipes have to be opened and closed in a water treatment system with the help of shut-off
devices.
An actuation option for the shut-off valve will be sought out by means of a test setup.
Layout
Shut-off device


1. The gate is opened when a pushbutton is pressed.
2. When the pushbutton is released, the gate is once again closed.
General conditions
• A double-acting cylinder will be used.
• The cylinder will be controlled with a pushbutton.
• In the event of a power failure, the cylinder’s piston rod should be retracted to the rear end position.
Work assignments
1. Compare directly actuated and pilot-actuated solenoid valves.
2. Describe the function of a solenoid valve.
3. Explain the meaning of the term IP.
4. Describe the significance of the circuit symbols for pneumatic cylinders.
Work aids
• Books of tables

1. Comparing pilot-actuated and directly actuated valves
– With regard to the type of valve piston actuation, differentiation is made between directly actuated and
pilot-actuated solenoid valves.
Compare these two valve types and list their respective advantages and disadvantages.
Directly actuated valve

When push button is actuated the valve will either opens of close
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Pilot-actuated valve
When push button is actuated, the sensor will actuated causing the valve to move
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2. The function of a solenoid valve
A valve symbol indicates how the respective valve functions, i.e. how many ports it has,
its switching positions and type of actuation – but it says nothing about its engineering
design.
– Describe the function of the directional control valve which is represented by means of the following
circuit symbol and cutaway view.
5/2 Way valve flow from 1-2, 4-5 solenoid actuated with manual override, spring returned
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Function
Used in double acting cylinders
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3. IP designation
Electrical equipment is protected by housings and covers depending on installation

and environmental conditions. The required level of protection against dust, moisture
and foreign matter must be identified.
– The designation IP 65 appears on a solenoid coil.
Explain the meaning of this designation.
Protection on ingress dust and water jets (IP: International Protection)

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4. Circuit symbols for pneumatic cylinders
Cylinders with piston rods which move in straight lines can be subdivided into two
groups.
• Single-acting cylinders
• Double-acting cylinders
– Describe the significance of the circuit symbols shown below for pneumatic cylinders.
Used in the opening of certain pipe connections

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– Complete the pneumatic and electrical circuit diagrams for the shut-off device. Supplement any



to this end.
CAUTION
• Risk of injury when switching on the compressed air!
If compressed air tubing slips off, shut off the compressed air supply immediately.

Initial position
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Step 1-2
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Step 2-3
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Exercise 3: Sealing cans
Learning objectives
• You’ll be familiar with the setup and function of a relay.
• You’ll be able to make use of indirect electrical actuation.

Half liter cans are filled with wall or ceiling paint at a manual workstation. The lids are press fitted with a
pneumatic press.
Layout
Sealing cans
Safety devices that are required in actual practice are not shown.


1. The cans are manually inserted into the press.
2. After pressing a pushbutton, the press cylinder is advanced and the lid is press fitted.
3. When the pushbutton is released, the press cylinder is retracted to its initial position.
4. The sealed cans are removed manually.
General conditions
• Control of the cylinder will be executed indirectly by means of a pushbutton.
• In the event of an electrical power failure, the cylinder’s piston rod should be retracted to the rear end
position.
Work assignments
1. Describe the setup and function of a relay.
Work aids
• Books of tables

1. The function of a relay
Relays are amongst the components used in the signal processing section. A relay is an
electromagnetically actuated switch with several contacts.
Relay – cutaway view
a) Match the numbers in the cutaway view of the relay to the components in the table.
Number Component
7 Relay coil terminal lugs
3 Coil winding
5 Contact set
2 Return spring
4 Armature
6 Switch contact terminal lugs
1 Coil with core

b) Describe the mode of operation of a relay.
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c) A relay coil can be used to switch one or more contacts. Depending upon the required function, relays
with normally closed, normally open or changeover contacts are used.
Describe the layouts, the contact line-ups and the functions of the depicted relays.
Layout, contact line-up
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Function
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Layout, contact line-up
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Function
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d) List the different ways in which relays can be used in electrical and electro-pneumatic controllers.
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– Complete the pneumatic and electrical circuit diagrams for the lid press. Supplement any incomplete
circuit symbols. Label the individual components and enter the missing port designations.




• Set the one-way flow control valves to match the specified retraction and advancing times of approx.
1 second. Use a stopwatch to this end.
CAUTION

Initial position
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Step 1-2
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Step 2-3
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Exercise 4: Filling plastic pellets
Learning objectives
• You’ll e able to set up indirect actuation.
• You’ll be familiar with logic operations
• You’ll be able to select solenoid valves based on the specified requirements.
• You’ll be able to convert solenoid valves.

Plastic pellets need to be filled from a storage silo. The silo is opened and closed with a flap. The process
will be started from two locations.
Layout
Filling plastic pellets


1. The flap is opened by pressing either one of two pushbuttons, and the bulk material is emptied out of
the container.
2. When the pushbutton is released, the flap is closed.
General conditions
• A single-acting cylinder will be used.
• Control of the cylinder will be executed indirectly and by means of a pushbutton.
• In the event of an electrical power failure, the cylinder’s piston rod should be advanced to the forward
end position.
Work assignments
1. Answer the questions concerning the conversion of solenoid valves.
2. Select a suitable solenoid valve for the application.
3. Explain the OR function.
Work aids
• Books of tables

1. Converting solenoid valves
A great variety of different demands are placed upon valves in actual industrial use. If a
valve with all of the desired characteristics is not available, a valve with a different
number of ports can often be used in order to fulfill the specified function. The
following table shows a selection of directional control valves which are frequently
used in industrial applications.
– Describe the valve types depicted in the table below.
Tick off all of the solenoid valves which can be replaced by a 5/2-way solenoid valve of the type shown
above.
Complete the circuit symbols such that the desired valve function is achieved.
 Substitution possible
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The term “conversion” includes even very simple measures, for example closing
working port 2 or 4 with a blanking plug.
2. Selecting solenoid valves
A valve is selected on the basis of the following criteria:

• Task
• Required performance in the event of power failure
• Lowest possible overall costs
The following valves are available for actuating a single-acting cylinder.

• A pilot-actuated 3/2-way solenoid valve with spring return and manual override
• A pilot-actuated 5/2-way solenoid valve with spring return and manual override

– Select a valve and justify your decision.
Selected valve type
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Reason
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In addition to the costs mentioned above, the overall costs of a valve also include
expenses for installation and maintenance, as well as warehousing costs for
replacement parts.

3. Logic operations: the OR function
It will be necessary to cause the piston rod of a cylinder to retract with two
pushbuttons, namely -SF1 and -SF2. If at least one of these pushbuttons is activated,
solenoid coil -MB1 is energized. As a result, solenoid valve -QM1 is switched to the
actuated position and the cylinder’s piston rod is retracted.
When both pushbuttons are released, the solenoid valve is switched to its initial
position and the piston rod is advanced
– Create the associated functions table and the logic symbol.
-SF1 -SF2 -MB1 -QM1
0 (not actuated)
0 (not actuated)
1 (actuated)
1 (actuated)
Functions table
Logic symbol
0 means pushbutton is not activated and the piston does not advance.
1 means pushbutton is activated and the piston advances.

– Complete the hydraulic and pneumatic and electrical circuit diagrams for the flap. Supplement any




to this end.
CAUTION

Initial position
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Step 1-2
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Step 2-3
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Exercise 5: Diverting packages
Learning objectives
• You’ll be familiar with the setup and function of a double-acting cylinder.
• You’ll be familiar with the setup and function of a double solenoid valve.
• You’ll be able to represent a simple control sequence in GRAFCET.

Packages will be diverted from one conveyor to another by means of a diverter.
Layout
Diverter


1. The diverting gate is advanced when one of the pushbuttons is activated. The package is transferred
and transported further.
2. The diverting gate is returned to its initial position when the second pushbutton is activated.
General conditions
• The cylinder will be controlled indirectly by means of a pushbutton. In the event of an electrical power
failure, the cylinder’s piston rod should remain in the current end position.
Work assignments
1. Select a solenoid valve for the application.
2. Describe the function of a solenoid valve.
3. Calculate the current consumption of a solenoid coil.
9. Represent the control sequence as a GRAFCET.
Work aids
• Books of tables

1. Using solenoid valves
Two factors need to be taken into consideration when deciding which type of valve will
be used for a specific application.
• Duration or time frame
• Number or frequency
of the required switching operations
In order to make most efficient possible use of a directional control valve, it must be
decided from case to case which is more economical for the respective application:
• A double solenoid valve, or
• A solenoid valve with spring return
– Decide whether a double solenoid valve or a solenoid valve with spring return is more economically
suited for each of the applications listed below, and give reasons for your selection.
Application 1
The clamping cylinder in a milling fixture must clamp a workpiece for the duration of the milling
process (roughly 10 minutes with 60 clamping operations per day).
Selected valve type

5/2-way solenoid valve at both sides
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Reason
Since there is a time delay at retracting the cylinder, it is more efficient to use double solenoid valve
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Application 2
The ejector cylinder in a sorting device will push defective workpieces from a conveyor belt (duration
of roughly 1 second with 600 clamping operations per day).
Selected valve type
5/2 way solenoid actuated, spring return

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Reason
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2. The function of a solenoid valve
– Describe the function of the directional control valve which is represented by means of the following
circuit symbol and cutaway view.
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Function
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3. Calculating the current consumption of a solenoid coil.
a) A solenoid valve with spring return will be switched with pushbutton -SF1.
Calculate current consumption and power for solenoid coil -MB1 based on 24 V DC supply power and a
coil resistance of 48 Ω (Ohm).
Current consumption of solenoid coil -MB1
Power consumption for -MB1

b) If the solenoid coil in question were connected to 24 V AC, would power consumption at -MB1 be higher
or lower. Give reasons for your answer.
 Current consumption is the same.

 Current consumption is higher.
 Current consumption is lower.
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– Complete the pneumatic and electrical circuit diagrams for the diverter. Supplement any incomplete
circuit symbols. Label the individual components and enter the missing port designations.
Pneumatic circuit diagram

Electrical circuit diagram



to this end.
CAUTION

Initial position
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Step 1-2
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Step 2-3
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9. Representing the sequence in GRAFCET
For a technology-independent representation of the GRAFCET, use the designations of

the pushbuttons, for example, as input variables, and the designation of the drive as
output variables.
a) Represent the diverter’s control sequence as a GRAFCET. Supplement the step enabling conditions
(transition conditions) for triggering each respective following step. Add comments to the steps and the
step enabling conditions.
b) Describe the steps and the step enabling conditions.
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Exercise 6: Pushing boards out of a stacking magazine
Learning objectives
• You’ll be able to allocate the components of an electropneumatic control system to the pneumatic
and/or the electrical circuit diagram.
• You’ll be familiar with the setup and function of a limit switch.
• You’ll be familiar with one of the options for end position sensing in cylinders.
• You’ll be able to prepare switching element tables for relays.

Wooden boards need to be pushed out of a stacking magazine and into a mounting device.
Layout
Stacking magazine


1. A wooden board is pushed out of the stacking magazine with a slide after pressing a pushbutton.
2. After reaching the front end position, the slide is returned to its initial position.
General conditions
• The cylinder’s front end position needs to be sensed.
Work assignments
1. Allocate the components of an electropneumatic system to the pneumatic and electrical circuit
diagrams.
2. Explain the design and function of limit switches.
3. Create switching element tables for the specified circuit diagrams.
Work aids
• Books of tables

1. Allocating components within an electropneumatic system
– The components of an electropneumatic system are represented in the pneumatic and/or electrical
circuit diagrams.
Indicate in which diagram the following components are include.
Component Pneumatic circuit diagram Electrical circuit diagram
Manually actuated pushbutton
Cylinder
Valves
Solenoid coils
Relay
Electromechanical limit switch
Electronic proximity switch
Indicator units
2. Describe the design and function of a limit switch
a) Match the numbers in the graphic to the components in the table.
Number Component
1 Guide bolt
4 Contact blade
3 Roller lever
2 Forced release lever
Limit switch – circuit symbol and cutaway view

b) Which function(s) can an electro-mechanical limit switch in an electro-pneumatic controller execute?
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c) Describe the design and function of the components represented by the following
circuit symbols.
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d) Which function(s) can an electro-mechanical limit switch in an electro-pneumatic controller execute?
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3. Preparing switching element tables
a) One way of recording the contacts controlled by a relay is to list them in a switching elements table.
Create switching element tables for relays -KF6 and -KF9.
Switching element Description
-KF6
-KF9
Switching element table

Another way of recording the contact sets controlled by a relay is shown in the
following circuit diagram.

b) Complete the entries for the relays listed in the table. Designate the current path within which the
respective contact is used, as well as the function fulfilled by the set of contacts (normally open or
normally closed).
Relay Current path Function: NO Function: NC
Relay -KF9
Relay -KF10
– Complete the pneumatic and electrical circuit diagrams for the ejector device. Supplement any



• Use the circuit diagram.

• Set the one-way flow control valves so that advancing and retracting times of approximately 1 second
are maintained. Use a stopwatch to this end.
CAUTION

Initial position
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Step 1-2
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Step 2-3
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Exercise 7: Optimizing the inspection of beverage crates
Learning objectives
• You’ll be able to calculate piston forces on the basis of specified values.
• You’ll be able to calculate characteristic electrical values.
• You’ll be able to make use of indirect actuation.
• You’ll be familiar with the logic AND operation and will be able to set it up.
• You’ll be able to describe a controller sequence in GRAFCET.

Beverage crates are checked for completeness with the help of an inspection unit. Incomplete crates are
pushed off of the roller conveyor by pressing a pushbutton. Problems occur repeatedly with the setup used
thus far. The pushbutton is not pressed long enough and, as a consequence, the single-acting cylinder
doesn’t advance to the front end position. The ejected beverages crates become jammed in the ejection
area.
Develop a controller with which this problem can be eliminated
Layout
Inspection unit for beverage crates


1. The cylinder of a piston rod should advance as soon as pushbutton -SF1 is activated.
2. After the piston rod reaches the front end position and activates a limit switch, it should be retracted
automatically.
General conditions
• Control of the cylinder will be executed indirectly with pushbuttons and electro-mechanical limit
switches.
• Advancing can only be started when the piston rod is in the rear end position.
Work assignments
1. Calculate the piston force of a double-acting cylinder.
2. Calculate the characteristic electrical values of a relay coil.
3. Explain the AND function.
4. Complete the electrical circuit diagram.
6. Describe the inspection unit sequence in GRAFCET
Work aids
• Books of tables

1. Calculating piston force
Theoretical piston force is calculated using the following formula:
Fth = A ⋅ p
For double-acting cylinders, the following applies:

Forward stroke Feff =(A ⋅ p) – FR Return stroke Feff = (A' ⋅ p) – FR
Feff Effective piston force (N)

A Useful piston area (m2) A' Useful piston ring area (m2)
D2 ⋅ π (D2 − d 2 ) ⋅ π
( )
4 4
p Working pressure (Pa) cFR Friction force (approx. 10% of Fth) (N)
D Piston diameter (m) d Piston rod diameter (m)
– Calculate effective piston force during the return stroke for the cylinder in question at a working
pressure of 600 kPa (6 bar).
Calculating piston surface area Calculating piston ring surface area

Calculating piston force, forward stroke Calculating piston force, return stroke
Consult the cylinder data sheet for the necessary data.

2. Calculating characteristic electrical values
The following applies to electrical power:

U2
P= U ⋅ I or P= or = I2 ⋅R
P
R
– It is known that the coil in a relay has a power rating of 1 W. Measurement of resistance between
terminals A1 and A2 resulted in a value of 580 Ω.
Calculate the relay’s operating voltage.

3. The AND function
It will be necessary to cause the piston rod of a cylinder to advance with two
pushbuttons, namely -SF1 and -SF2. When both pushbuttons are activated
simultaneously, solenoid coil -MB1 is energized, solenoid valve -QM1 switches to the
actuated position and the piston rod advances.
When at least one of the two pushbuttons is released, the valve is switched back to its
initial position and the piston rod is retracted.
– Create the associated functions table and draw the logic symbol.
-SF1 -SF2 -MB1 -QM1
Functions table
logic symbol
0 means pushbutton is not activated and the piston does not advance.
1 means pushbutton is activated and the piston advances.

4. Completing the electrical circuit diagram
a) Set up the pneumatic controller in accordance with the circuit diagram.
b) Complete the electrical circuit diagram for the sorting device. Supplement any incomplete circuit
symbols. Label the individual components and enter the missing port designations.


6. Describing the sorting device in GRAFCET
a) Create the GRAFCET for the sorting device. Enter the step enabling conditions and actions to this end.
Add comments to the steps and step enabling conditions.
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to this end.
CAUTION
Initial position
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Step 1-2
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Step 2-3
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Exercise 8: Shifting roller conveyors
Learning objectives
• You’ll be familiar with logic functions and be able to set them up.
• You’ll be able to explain and set up an electrical latching circuit with dominant breaking signal.

Workpiece carriers are transported on roller conveyors. One of the segments of the roller conveyor can be
shifted with the help of a pneumatic drive. This makes it possible to transfer the workpiece carriers to
another roller conveyor.
Layout
Roller conveyors with shiftable segment


1. The piston rod of a cylinder is advanced when pushbutton -SF1 is activated.
2. The piston rod is retracted when pushbutton -SF2 is pressed.
General conditions
• The cylinder will be controlled indirectly.
Work assignments
1. Describe different signal storage options.
2. Analyze performance of a circuit in the event of a power failure.
3. Explain the NOT function.
Work aids
• Books of tables

1. Signal storage
If the piston rod of a cylinder needs to be advanced even when the pushbutton is
pressed only briefly, activation of the pushbutton must be stored. The signal can be
stored either in the power section or in the signal control section of the circuit
– Describe how signal storage is implemented in the power section or the signal control section.
Signal storage in the power section
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Signal storage in the signal control section
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2. Analyzing the circuits
– Describe the performance of the circuit shown below (pilot-actuated 5/2-way solenoid valve with spring
return and manual override, double-acting cylinder) in the event of electrical power failure and
compressed air supply failure.
Electrical power failure
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Compressed air supply failure
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3. Logic functions: the NOT function
Signal lamp -PF1 should always light up when pushbutton -SF1 is not activated.
– Create the associated functions table and the logic symbol.
-SF1 -PF1
Functions table
Logic symbol
0 means pushbutton -SF1 not activated or lamp -PF1 off.

1 means pushbutton -SF1 activated or lamp -PF1 on.

– Complete the pneumatic and electrical circuit diagrams for the shifting fixture. Supplement any




to this end.
CAUTION
Initial position
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Step 1-2
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Step 2-3
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Exercise 9: Transferring bottles
Learning objectives
• You’ll be familiar with latching circuits with varying performance features.
• You’ll be familiar with various types of end position monitoring.
• You’ll be able to select the appropriate type of end position monitoring for a pneumatic cylinder.

Bottles need to be diverted in groups of three from one conveyor to another by means of a diverter. After
being switched on, the system should run continuously. It should not be switched off until a stop signal is
generated.
Layout
Diverter for bottles


1. The sequence is started by pressing a pushbutton.
2. If three bottles are present, the diverting cylinder’s piston rod is advanced.
3. The bottles are diverted and transported to a second conveyor belt.
4. The sequence is stopped by pressing a second pushbutton.
General conditions
• The utilized latching circuit should demonstrate dominant off characteristics.
Work assignments
1. Store the signals with a latching circuit.
2. Describe the setup and function of a magnetic proximity switch.
3. Select end position monitoring for a pneumatic cylinder.
Work aids
• Books of tables

1. Storing signals with a latching circuit
A relay circuit with self-latching loop is required in order to store a signal in the signal
control section. The relay coil is energized when pushbutton -SF1 (normally open) is
activated.
In order to clear self-latching, supply power to the relay coil must be interrupted.
Additional pushbutton -SF2 (normally closed) is required to this end. Depending upon
how this NC contact is arranged, we differentiate between two types of self-latching.:
• Dominantly setting self-latching
• Dominantly resetting self-latching
a) Complete the circuit diagrams shown below such that the relay is self-latching after pushbutton -SF1 is
released. Self-latching must be cleared when pushbutton -SF2 is activated.
Electrical circuit diagram, left: dominantly resetting self-latching, right: dominantly setting self-latching

Different signal storing circuits demonstrate different characteristics:

• In the event of simultaneous occurrence of setting and resetting conditions
• In the event of failure of electrical control energy or wire break
b) Expand the table and indicate how each respective valve responds.
Signal storage by means of Signal storage by means of electrical latching circuit combined
a double solenoid valve with spring return valve
Dominantly setting Dominantly resetting
Simultaneous setting and

resetting signal
Electrical supply power failure
2. Describing the setup and function of a magnetic proximity switch
Magnetic proximity switch (reed switch) – circuit symbol and cutaway views

a) Describe the setup and function of a magnetic proximity switch (reed switch).
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b) Describe the setup and function of a magneto-resistive proximity switch.
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3. Selecting end position monitoring for pneumatic cylinders
Limit switches and proximity switches are assigned the task of acquiring information
and forwarding it to signal processing.
They include:
• Mechanical position switches (limit switches)
• Magnetic proximity switches
• Inductive proximity switches
• Optical proximity switches
• Capacitive proximity switches
a) Match up the terms to the corresponding circuit symbols in the table.
Circuit symbol Designation

b) List different types of end position monitoring for pneumatic cylinders.
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The front end position of a pneumatic cylinder is to be monitored with a proximity

sensor. The proximity sensor must fulfill the following requirements:
• The proximity sensor should provide an electrical output signal.
• The piston rod’s end position must be sensed in a contactless fashion.
• The proximity sensor must function in a non-contacting fashion.
• The proximity sensor should be insensitive to dust and vibration.
• A permanent magnet must be attached to the cylinder’s piston.
c) Select a suitable proximity sensor and explain why it fulfils the specified requirements.
 Pneumatic proximity sensor

 Mechanical limit switch
 Reed proximity switch
 Magneto-resistive proximity sensor
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a) Complete the pneumatic circuit diagram

for the diverter. Add any missing circuit
symbols. Label the individual components.
b) Complete the electrical circuit diagram for the diverter. Add any missing circuit symbols. Identify the
individual components and enter the missing port designations.

components to the tables below.



• Adjust the magnetic proximity sensors.
CAUTION

Initial position
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Step 1-2
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Step 2-n
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Step n-(n+1)
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Exercise 10: Stamping mounting wedges
Learning objectives
• You’ll be familiar with the setup and function of pressure sensors.
• You’ll be able to set up pressure-dependent control systems.
• You’ll be able to describe a controller sequence in GRAFCET.

Mounting wedges are required for the production of door frames. The wedges will be stamped with a
stamping fixture.
Layout
Stamping fixture


1. The stamping tool is advanced after pressing a pushbutton, and a mounting wedge is stamped.
2. After stamping pressure is reached, the stamping tool is retracted to its start position.
General conditions
• Working pressure should be 550 kPa (5.5 bar).
Work assignments
1. Describe the function of a pressure sensor.
2. Describe the stamping fixture’s sequence in GRAFCET
Work aids
• Books of tables
1. Describing the function of a pressure sensor
Pressure-sensitive sensors, so-called pressure switches, are used in order to measure

and monitor pressure within the system.
a) Describe the mode of operation of a pneumatic-electric converter.
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Pressure sensors can be subdivided into two groups. Differentiation is made between:
• Pressure sensors with mechanical contact (mechanical mode of operation)
• Pressure sensors with electronic switching (electronic mode of operation
b) Describe the task and the function of the pressure switch depicted below.
Electrical
Pneumatic
Pressure switch – circuit symbols and cutaway view
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c) Describe the function of the utilized pressure sensor.
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d) Complete the circuit symbol for the pressure sensor.
Requirements:
• The pressure sensor is electronically adjustable,
• has an adjustable switching output,
• an analogue voltage output and
• it has a digital display for the measured pressure value.

2. GRAFCET
a) Create the GRAFCET for the stamping fixture. Add the step enabling conditions and actions to this end.
Add comments to the steps and step enabling conditions.
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a) Complete the pneumatic circuit diagram for the

stamping fixture. Add any missing circuit
symbols. Identify the components.
b) Complete the electric circuit diagram for the stamping fixture. Add any missing circuit symbols. Label
the individual components and enter the port designations.

Double-acting cylinder
One-way flow control valve
5/2-way double solenoid valve
2 -MB1, -MB2 Solenoid coils for 5/2-way double solenoid valve -QM1



• Adjust the pressure sensor such that it generates an output signal at the specified pressure value.
CAUTION

Initial position
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Step 1-2
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Step 2-3
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Exercise 11: Palletizing roof tiles
Learning objectives
• You’ll be able to make use of an optical proximity sensor.
• You’ll be familiar with sequence descriptions and will be able to prepare them for specified sequences.
• You’ll be able to implement controllers with two cylinders.

Stacked roof tiles are lashed together with a plastic strap. The resulting stacks are then transported to a
pallet loading station, at which they’re pushed onto Euro pallets.
Layout
Roof tile strapping and pallet loading station


1. When magnetic proximity switch -BG1 is activated and pushbutton -SF1 is pressed, the piston rod in
loading cylinder -MM1 is advanced. The individual packet thus arrives at its loading position and
proximity sensor -BG2 is activated.
2. The piston rod in ejectorcylinder -MM2 advances and pushes the packet onto the pallet. Optical
3. When proximity sensor -BG3 is activated, the piston rods in cylinders -MM1 and -MM2 are retracted.
The overall sequence is thus as follows:

-MM1+ -MM2+ -MM1–
-MM2–
General conditions
• Adjust the one-way flow control valves such that both cylinders are retracted at the same speed.
• The front end position of the single-acting ejectorcylinder must be detected by an optical proximity
sensor.
Work assignments
1. Describe the function of the optical proximity sensor.
2. Prepare the specified sequence descriptions for the process.
Work aids
• Books of tables

1. The function of the optical proximity sensor
a) Describe the function of the utilized optical proximity sensor.
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b) Enter the technical data to the table included below. Use the respective data sheet to this end
Technical data
Switching voltage
Residual ripple
Nominal switching distance
Switching frequency
Output function
c) Explain in writing what needs to be observed when setting up the circuit with regard to the position of
the proximity sensor.
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d) Sketch supply power into the drawing shown below, and connect the terminals at the optical proximity
sensor to supply power. Enter the connections to the table.
Connection socket Connection
Red (1) 24 V
Black (4) Relay (coil)
Blue (3) 0V
Circuit diagram, optical proximity sensor
2. Preparing the sequence descriptions for the process
a) Create a displacement-step diagram for the sequence described above.
Displacement-step diagram

b) Create a GRAFCET for the process described above.
GRAFCET for the pallet loading station
c) Describe the steps and the step enabling conditions.
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– Complete the pneumatic and electrical circuit diagrams for the pallet loading station Supplement any




• Adjust the pressure sensor such that it generates an output signal at the specified pressure value.

CAUTION
Initial position
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Step 1-2
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Step 2-3
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Step 3-4
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Exercise 12: Eliminating a malfunction at a pallet loading station
Learning objectives
• You’ll e able to detect and eliminate faults in simple electropneumatic controllers.

The pallet loading station comes to a standstill during operation. A malfunction has occurred and must be
eliminated. Afterwards, the pallet loading station has to be restarted.
Layout
Roof tile strapping and pallet loading station


1. When magnetic proximity switch -BG1 is activated and pushbutton -SF1 is pressed, the piston rod in
loading cylinder -MM1 is advanced. The individual packet thus arrives at its loading position and
2. The piston rod in ejectorcylinder -MM2 advances and pushes the packet onto the pallet. Optical
3. When proximity sensor -BG3 is activated, the piston rods in cylinders -MM1 and -MM2 are retracted.
The overall sequence is thus as follows:

-MM1+ -MM2+ -MM1–
-MM2–
General conditions
• A fault has occurred.
Work assignments
1. Familiarize yourself with the circuit and the control sequence.
2. Describe the essential steps required for systematic troubleshooting
3. Apply systematic troubleshooting to the fault in the sequence for the pallet loading station.
4. Describe the consequences of a broken wire in the electrical circuit
5. Pinpoint and describe the fault. Restart the controller.
Work aids
• Books of tables

1. Familiarizing yourself with the circuit and the control sequence
– Familiarize yourself with the controller’s function and its control sequence. Make use of the following
documentation and circuit diagrams to this end.
Displacement-step diagram
GRAFCET for the pallet loading station

Electrical circuit digram

2. Describing the essential steps required for systematic troubleshooting
– Briefly describe the procedure used for systematic troubleshooting.
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3. Applying the troubleshooting procedure to a fault in the sequence for the pallet loading station
The following fault occurs during the sequence for the pallet loading station:
• The piston rods in cylinders -MM1 -MM2 advance
• The controller fails during this step.
– Describe the possible causes of this fault.
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4. Describing the consequences of a broken wire in the electrical circuit
– A wire is interrupted at the points identified in the electrical circuit shown below.
Explain which effects a broken wire would have on the circuit’s function at each of the identified points.
Broken wire in the earth cable from relay -KF1, current path 2
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Interrupted wire in signal line, proximity sensor -BG2, current path 4
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Broken wire in the supply line, solenoid coil -MB1, current path 7
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Broken wire in supply line, relay contact 14 (relay -KF3), current path 8
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Broken wire in earth cable, solenoid coil -MB3, current path 9
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5. Pinpointing and describing the fault
a) Set up the controller for the container handling unit and assure that the control sequence runs correctly.
b) Ask your trainer to create a fault in the control sequence. Pinpoint and eliminate the fault by means of
systematic troubleshooting.
c) Process this work assignment in the order of the worksheets. Pinpoint the fault at the controller and
eliminate it. Restart the controller.

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Exercises and worksheets

Exercise 1: Inspecting beverage crates ________________________________________________________ 3

© Festo Didactic 541090 1

Description of the problem

Develop a controller with which this process can be executed

Inspection unit for beverage crates

© Festo Didactic 541090 3

Description of the process

4 Name: __________________________________ Date: ____________ © Festo Didactic 541090

1. Function of pneumatic power components

Pneumatic power components can be subdivided into two groups:

– Describe the power components shown below and their functions.

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 5

2. Circuit symbols for solenoid valves

6 Name: __________________________________ Date: ____________ © Festo Didactic 541090

3. Identification of valve ports

Port designation Meaning and function

12 Open flow from 1 to 2

10 blocks flow from 1 to 2

82/84 Pilot Air

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 7

4. Directional control valve neutral position

3/2-way solenoid valve, normally closed

3/2-way solenoid valve, normally open

8 Name: __________________________________ Date: ____________ © Festo Didactic 541090

5. Functions of various valve types

Solenoid valve with spring return

Double solenoid valve

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 9

6. Direct and indirect actuation

10 Name: __________________________________ Date: ____________ © Festo Didactic 541090

7. Design and function of electrical switches

– Describe the design and function of the switches depicted below.

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 11

8. Completing the pneumatic and electrical circuit diagrams

Pneumatic circuit diagram Electrical circuit diagram

12 Name: __________________________________ Date: ____________ © Festo Didactic 541090

9. Completing the equipment list

Quantity Identification Designation

1 -XM1 Distributor block

1 -AZ1 On-off valve with filter regulating valve

1 – Compressed air source

Quantity Identification Designation

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 13

11. Double checking the control system setup

12. Describing the controller sequence

– Describe the individual steps of the controller sequence.

14 Name: __________________________________ Date: ____________ © Festo Didactic 541090

Description of the problem

© Festo Didactic 541090 15

Description of the process

16 Name: __________________________________ Date: ____________ © Festo Didactic 541090

1. Comparing pilot-actuated and directly actuated valves

Directly actuated valve

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 17

2. The function of a solenoid valve

18 Name: __________________________________ Date: ____________ © Festo Didactic 541090

Electrical equipment is protected by housings and covers depending on installation

– The designation IP 65 appears on a solenoid coil.

Explain the meaning of this designation.

Protection on ingress dust and water jets (IP: International Protection)

© Festo Didactic 541090 Name: __________________________________ Date: ____________ 19

4. Circuit symbols for pneumatic cylinders

Used in the opening of certain pipe connections

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